Article of footwear comprising reusable waste and surplus materials

ABSTRACT

An article of footwear and a method of manufacturing are provided. The article comprises an upper fixedly attached to a sole structure. The upper may comprise a wall wherein an inner layer is coupled to an outer layer, such that the inner layer and the outer layer define a closed pocket therebetween. A layer of scrap particulate matter is disposed in the closed pocket, and is at least partially visible through the outer layer, which is formed of a sufficiently transparent material. The sole structure is fabricated from a mixture of discrete pieces of scrap particulate matter and virgin polymer material, such that the discrete pieces of scrap particulate matter are at least partially visible on the outer surface of the sole structure. The sole structure is further substantially covered in a plurality of cavities and a plurality of protrusions, such that the outer sole surface has a crater-like texture.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of priority from U.S. Provisional Patent Application No. 63/151,275, filed on 19 Feb. 2021, which is incorporated by reference in its entirety.

TECHNICAL FIELD

The present disclosure generally relates to an article of footwear comprising reusable waste and surplus materials and a method of manufacturing an article of footwear using reusable waste and surplus materials.

BACKGROUND

Footwear often includes many components of many different materials. An article of footwear typically includes an upper that is operative to receive a foot of a wearer, and a sole structure configured to be located under a wearer's foot to space the foot away from the ground. The sole structure often includes a rubber or foamed elastomeric material that is suitable for attenuating ground impact forces.

It has been estimated that each year over 300 million pairs of shoes are thrown away globally. In the past, it was common for waste material from these shoes to simply be discarded. Further, the footwear manufacturing process produces surplus material in the initial formation of an article of footwear, e.g. offcuts, salvage, or scrap which were also often discarded. More recently, techniques have been developed to incorporate recycled waste and formation surplus material into new shoes. These techniques typically involve separating the waste and/or excess surplus materials into small pieces, generally referred to as “regrind.”

SUMMARY

The presently disclosed technology adopts a sustainable and environmentally conscious approach to footwear manufacturing, which contemplates that waste material from discarded shoes may be ground or shredded, etc. and recycled to form re-usable “green regrind material”, and that excess surplus material such as offcuts, salvage, or scrap material produced during initial shoe formation may be ground or shredded, etc. and recycled to form re-usable “grey regrind material”. These re-usable “green regrind materials” and “grey regrind materials” may be further incorporated into new shoes or footwear applications. More particularly, the presently disclosed technology involves a manner of constructing an article of footwear that incorporates green and/or grey regrind materials into each of the sole structure and an outer wall of the upper of the footwear article.

In general, the article of footwear may comprise a sole structure and an upper fixedly attached to the sole structure. The upper may include a wall that at least partially surrounds an interior volume operative to receive a foot of a wearer. The wall may further comprise an inner layer and an outer layer coupled to the inner layer, such that the inner layer and the outer layer define a closed pocket therebetween. At least one of a grey regrind material, a green regrind material, and/or a combination of green regrind material and grey regrind material may be disposed within the closed pocket between the outer layer and inner layer of the upper. The outer layer may be formed of a sufficiently transparent material, such that the grey regrind material, green regrind material, and or a combination thereof may be at least partially visible through the outer layer, thereby providing a unique visual effect, while also improving the cushioning and/or ventilation properties of the upper.

In such an instance, the upper may be formed via a manufacturing process workflow for forming the upper, wherein reusable materials, namely recycled materials, excess surplus materials, such as offcuts, salvage, or scrap materials may be obtained or received; regrind material, particularly green regrind material or grey regrind material, may be formed by dividing the reusable scrap material into a plurality of discrete pieces of scrap particulate matter via at least one of a grinding process and a shredding process; the discrete pieces of scrap particulate matter form a layer of scrap particulate matter; and the layer of scrap particulate matter is inserted into a closed pocket formed between the inner layer of a wall of an upper and the outer layer of the wall of the upper of the article of footwear.

Further aspects of the present disclosure are directed to a sole structure, which comprises a first plurality of discrete pieces of reusable scrap particulate matter, such as at least one of a grey regrind material, a green regrind material, and/or a combination of green regrind material and grey regrind material therein, bonded together with a virgin polymer material. In this way, the reusable scrap particulate matter forms multiple distinctly shaped, sized, and colored fragments, all of which are erratically dispersed throughout the sole structure, such that more than one of the discrete pieces of reusable scrap particulate matter are visible on the outer sole surface. Optionally, in some instances the outer sole surface of the sole structure may include fifty or more distinctly shaped/colored reusable scrap particulate fragments.

Further, the sole structure may be formed or machined with multiple distinctly shaped and sized cavities and multiple distinctly shaped and sized protrusions defined by the outer sole surface. For at least some configurations, the entire outer sole surface of the sole structure is substantially covered with the erratically dispersed cavities and protrusions. Optionally, the sole structure is provided with fifty or more distinctly shaped cavities and fifty or more distinctly shaped protrusions, such that the outer sole surface takes on a crater-like appearance. An attendant advantage to sole structures formed with an outer surface that defines fifty or more distinctly shaped/colored reusable scrap particulate fragments, fifty or more distinctly shaped cavities, and fifty or more distinctly shaped protrusions is that no two sole structures will be identical.

In such an instance, the sole structure may be formed via a manufacturing process workflow for fabricating a sole structure of an athletic shoe using a grey regrind material, a green regrind material, and/or a combination of green regrind material and grey regrind material with virgin rubber or elastomeric materials or resins such as thermoplastic elastomers (TPE) or ethylene-vinyl acetate (EVA) copolymers, as well as a foaming agent. The mixture may then be subjected to one of a compression molding, injection molding, or the like.

In one example, the representative method includes receiving reusable materials, namely recycled materials, excess surplus materials, such as offcuts, salvage, or scrap materials; forming regrind material, particularly green regrind material or grey regrind material, by dividing the reusable material into a first plurality of discrete pieces of scrap particulate matter via at least one of a grinding process and a shredding process; mixing the discrete pieces of scrap particulate matter with a virgin polymer material and a foaming agent to form a sole structure mixture; placing the sole structure mixture into an internal cavity of a final mold, which is shaped like the sole structure; forming the sole structure by heating the processed sole structure mixture past a threshold activation temperature of the foaming agent, such that the foaming agent causes the scrap particulate matter to expand and fill the internal cavity of the final mold; and extracting the formed sole structure from the mold.

The above summary is not intended to represent every embodiment or every aspect of the present disclosure. Rather, the foregoing summary merely provides an exemplification of some of the novel concepts and features set forth herein. The above features and advantages, and other features and attendant advantages of this disclosure, will be readily apparent from the following detailed description of illustrated examples and representative modes for carrying out the present disclosure when taken in connection with the accompanying drawings and the appended claims. Moreover, this disclosure expressly includes any and all combinations and sub combinations of the elements and features presented above and below.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings described herein are for illustrative purposes only, are schematic in nature, and are intended to be exemplary rather than to limit the scope of the disclosure.

FIG. 1 is a schematic, perspective view of a lateral side of a first example article of footwear.

FIG. 2 is a schematic, perspective view of a lateral side of a second example article of footwear.

FIG. 3 is a schematic, perspective view of a lateral side of a third example article of footwear.

FIG. 4 is a schematic, perspective view of a medial side of the first example article of footwear.

FIG. 5 is a schematic, perspective view of the medial side of the second example article of footwear.

FIG. 6 is a schematic, perspective view of the medial side of the third example article of footwear.

FIG. 7 is a schematic, perspective, partially-exploded view of the first example article of footwear.

FIG. 8 is a schematic, perspective, plan view of the first example article of footwear.

FIG. 9 is a bottom-view of a representative sole structure of FIGS. 1-8.

FIG. 10 is a flow chart of the example method of manufacturing the article of footwear of FIGS. 1-9.

FIG. 11 is a flow chart further detailing an example step 103 of FIG. 10.

FIG. 12 is a flow chart further detailing an example step 104 of FIG. 10.

DETAILED DESCRIPTION

While the present disclosure may be described with respect to specific applications or industries, those skilled in the art will recognize the broader applicability of the disclosure.

The terms “a”, “an”, “the”, “at least one”, and “one or more” are used interchangeably to indicate that at least one of the items is present. A plurality of such items may be present unless the context clearly indicates otherwise. All numerical values of parameters (e.g., of quantities or conditions) in this specification, unless otherwise indicated expressly or clearly in view of the context, including the appended claims, are to be understood as being modified in all instances by the term “about” whether or not “about” actually appears before the numerical value. “About” indicates that the stated numerical value allows some slight imprecision (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If the imprecision provided by “about” is not otherwise understood in the art with this ordinary meaning, then “about” as used herein indicates at least variations that may arise from ordinary methods of measuring and using such parameters. In addition, a disclosure of a range is to be understood as specifically disclosing all values and further divided ranges within the range.

The terms “comprising”, “including”, and “having” are inclusive and therefore specify the presence of stated features, steps, operations, elements, or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, or components. Orders of steps, processes, and operations may be altered when possible, and additional or alternative steps may be employed. As used in this specification, the term “or” includes any one and all combinations of the associated listed items. The term “any of” is understood to include any possible combination of referenced items, including “any one of” the referenced items. The term “any of” is understood to include any possible combination of referenced claims of the appended claims, including “any one of” the referenced claims.

Features shown in one figure may be combined with, substituted for, or modified by, features shown in any of the figures. Unless stated otherwise, no features, elements, or limitations are mutually exclusive of any other features, elements, or limitations. Furthermore, no features, elements, or limitations are absolutely required for operation. Any specific configurations shown in the figures are illustrative only and the specific configurations shown are not limiting of the claims or the description.

For consistency and convenience, directional adjectives are employed throughout this detailed description corresponding to the illustrated embodiments. Those having ordinary skill in the art will recognize that terms such as “above”, “below”, “upward”, “downward”, “top”, “bottom”, etc., may be used descriptively relative to the figures, without representing limitations on the scope of the invention, as defined by the claims. Any numerical designations, such as “first” or “second” are illustrative only and are not intended to limit the scope of the disclosure in any way.

The term “longitudinal”, as used throughout this detailed description and in the claims, refers to a direction extending a length of a component. For example, a longitudinal direction of a shoe extends between a forefoot region and a heel region of the shoe. The term “forward” or “anterior” is used to refer to the general direction from a heel region toward a forefoot region, and the term “rearward” or “posterior” is used to refer to the opposite direction, i.e., the direction from the forefoot region toward the heel region. In some cases, a component may be identified with a longitudinal axis as well as a forward and rearward longitudinal direction along that axis. The longitudinal direction or axis may also be referred to as an anterior-posterior direction or axis.

The term “transverse”, as used throughout this detailed description and in the claims, refers to a direction extending a width of a component. For example, a transverse direction of a shoe extends between a lateral side and a medial side of the shoe. The transverse direction or axis may also be referred to as a lateral direction or axis or a mediolateral direction or axis.

The term “vertical”, as used throughout this detailed description and in the claims, refers to a direction generally perpendicular to both the lateral and longitudinal directions. For example, in cases where a sole is planted flat on a ground surface, the vertical direction may extend from the ground surface upward. It will be understood that each of these directional adjectives may be applied to individual components of a sole. The term “upward” or “upwards” refers to the vertical direction pointing towards a top of the component, which may include an instep, a fastening region and/or a throat of an upper. The term “downward” or “downwards” refers to the vertical direction pointing opposite the upwards direction, toward the bottom of a component and may generally point towards the bottom of a sole structure of an article of footwear.

In addition, the term “proximal” refers to a direction that is nearer a center of a footwear component, or is closer toward a foot when the foot is inserted in the article of footwear as it is worn by a user. Likewise, the term “distal” refers to a relative position that is further away from a center of the footwear component or is further from a foot when the foot is inserted in the article of footwear as it is worn by a user. Thus, the terms proximal and distal may be understood to provide generally opposing terms to describe relative spatial positions.

To assist and clarify the subsequent description of various embodiments, various terms are defined herein. Unless otherwise indicated, the following definitions apply throughout this specification (including the claims). An “article of footwear”, a “footwear article of manufacture”, and “footwear” may be considered to be both a machine and a manufacture. Assembled, ready to wear footwear articles (e.g., shoes, sandals, boots, etc.), as well as discrete components of footwear articles (such as a midsole, an outsole, an upper component, etc.) prior to final assembly into ready to wear footwear articles, are considered and alternatively referred to herein in either the singular or plural as “article(s) of footwear”. Waste material from discarded shoes, which may be ground or shredded, etc. and recycled may form re-usable material defined as “green regrind material”. Excess surplus material such as offcuts, salvage, or scrap material produced during initial shoe formation may be ground or shredded, etc. and recycled to form re-usable material defined as “grey regrind material”.

The following discussion and accompanying figures disclose various footwear configurations and methods relating to manufacturing of the same. Although the article of footwear 10 is depicted as athletic footwear configured for sports, such as sneakers, in the associated Figures, concepts associated with the configurations and methods may be applied to various other types of athletic footwear articles, such as a hiking boots and shoes, soccer shoes, football shoes, running shoes, cross-training shoes, rugby shoes, basketball shoes, etc. However, the article of footwear 10 is not limited to sneakers or other sports shoes. In some embodiments, the disclosed provisions may be configured for use with various kinds of non-sports-related footwear, including but not limited to, boots, leisure shoes, dress shoes, work shoes, sandals, slippers, or any other category of footwear, which may also incorporate concepts discussed herein.

In a general sense, the article of footwear 10 of the present disclosure is designed to be manufactured via an environmentally friendly and sustainable process. In this way, reusable scrap material, manufacturing surplus material, or recycled or reclaimed material from a discarded or unsellable shoes, is utilized in the formation of a newly-formed shoe, to reduce material waste. More particularly, recycled and/or reusable material from at least one of an upper and a sole structure of another article of footwear or the surplus material from the formation of at least one of an upper and a sole structure of another article of footwear is divided via one of a grinding process or shredding process into a plurality of discrete pieces of reusable scrap particulate matter 22, 23 also referred to as “regrind”. Regrind material, by definition, is material that has undergone at least one processing method and the subsequent sprue, runners, flash, or rejected parts are ground or chopped, paragraph 37—

Further, regrind 22, 23 is defined herein as a mixture of at least one of cured rubber granules, elastomeric granules, foam granules, textile pieces and fibers, leather pieces, and polymer pieces. Regrind 22, 23 may include ground and/or shredded waste from used, discarded, or unsellable footwear and/or ground or shredded surplus material or recycled scrap material from footwear manufacturing. Unless otherwise specified, the term “regrind” should not imply any specific process, but rather is intended to refer generally to sectioned pieces of post-consumer and/or post-manufacturing waste that has undergone at least one processing method and the subsequent sprue, runners, flash, or rejected parts resultant therefrom.

In one example, the regrind 22, 23 is a “grey regrind material”, which is defined as ground/shredded/cut/sectioned pieces of surplus material from footwear manufacturing, e.g., ground waste or scrap rubber from footwear manufacturing, ground waste or scrap foam from footwear manufacturing, ground or shredded waste, salvage, or scrap textile fibers (e.g., string, thread, yarn) from footwear manufacturing, or a combination thereof. In another example, the regrind 22, 23 is a recycled or “green regrind material” wherein the green regrind material consists of ground/shredded/cut/sectioned pieces of recycled, discarded, or unsellable footwear, e.g., ground cured rubber from footwear, ground foam from footwear, ground or shredded textile fibers from footwear, or a combination thereof. In such examples, the green regrind material is obtained from ground post-consumer waste, e.g., footwear waste, recycled post-consumer shoes, and/or ground portions of unsellable footwear.

The reusable particulate matter or regrind 22, 23 is then incorporated into one or more of the upper 12 and the sole structure 14. More particularly, the reusable particulate 22 may be inserted between an inner layer 18 and an outer layer 20 of a wall 15 an upper 12 of a newly formed article of footwear 10. To provide a unique visual effect, the outer layer 20 may be formed of a sufficiently transparent or translucent material, such that the regrind 22 is at least partially visible through the outer layer 20. Further, the reusable particular matter 23 may be incorporated into the sole structure 14, more particularly, the impact-mitigating midsole 19, and/or a surface-contacting outsole 17 thereof, such that the reusable particulate matter 23 forms multiple distinctly shaped, sized, and colored fragments, all of which are erratically dispersed on an outer surface 13 of the sole structure 14. Further, the sole structure 14 may be formed or machined with multiple distinctly shaped and sized cavities 35 and multiple distinctly shaped and sized protrusions 37. For at least some configurations, an entirety of the outer sole surface 13 of the sole structure 14 is substantially covered with the erratically dispersed cavities 35 and protrusions 37, such that the outer sole surface 13 takes on a crater-like appearance.

In addition to providing a means of recycling and reusing the material from post-consumer shoes and reclaiming surplus material from initial shoe formation, the present techniques provide the upper 12 with a more breathable and cushioned structure and the sole structure 14 with improved cushioning for the foot. Said another way, instead of the upper simply being a solid foam pad, pelletized grey regrind material or pelletized green regrind material can permit air and/or evaporated sweat to pass between the discrete granules, which can improve the comfort of the upper 12. Additionally, with respect to the upper 12 and the sole structure 14, because grey regrind material and green regrind material respectively, can each originate from materials of varying colors, the present techniques permit a shoe construction where the visible appearance of each shoe is unique. The uniqueness is attributable to the random dispersion of the regrind throughout the closed pocket 33 in the upper 12 and across the outer sole surface 13 in the sole structure 14. More specifically, each shoe 10 may take on a different appearance based on the available colors of regrind at the time of manufacture together with the dispersion process. This could promote an added consumer desirability for shoes that achieve aesthetically pleasing or unique designs or that have creative patterns or colors.

Referring to the drawings, wherein like reference numerals refer to like components throughout the several views, an article of footwear 10 is provided. As shown in FIGS. 1-9, the article of footwear 10 comprises an upper 12 fixedly attached to a sole structure 14.

The upper 12 is a portion of the article of footwear 10 that defines an interior volume or cavity 16 adapted to receive a foot of a wearer. The upper 12 in this disclosure further includes a wall 15 that at least partially surrounds the interior volume or cavity 16. For the purpose of consistency and clarity, the “interior” of the article of footwear 10 refers to space that is occupied by a wearer's foot when the article of footwear 10 is worn. The “inner side” of the wall 15 or other shoe element refers to the face of that panel or element that is (or will be) oriented toward the interior in a completed article of footwear 10. The “outer side” or “exterior” of an element refers to the face of that element that is (or will be) oriented away from the interior in a completed article of footwear 10.

As indicated in FIGS. 1-6, the article of footwear 10 may be divided into a forefoot region 34, a midfoot region 36, and a heel region 38, which are likewise the forefoot region 34, the midfoot region 36, and the heel region 38, of the sole structure 14 and the upper 12 respectively. The forefoot region 34 generally includes portions of the article of footwear 10 corresponding with the toes and the joints connecting the metatarsals with the phalanges. The midfoot region 36 generally includes portions of the article of footwear 10 corresponding with the arch area and instep of the foot. The heel region 38 corresponds with rear portions of the foot, including the calcaneus bone. The forefoot region 34, the midfoot region 36, and the heel region 38 are not intended to demarcate precise areas of the footwear 10 but are instead intended to represent general areas of the footwear 10 to aid in the following discussion.

The article of footwear 10 further has a lateral side portion 24 (FIGS. 1-3) and a medial side portion 26 (FIGS. 4-6). The lateral side portion 24 and medial side 26 portion extend through each of the forefoot region 34, the midfoot region 36, and the heel region 38, and correspond with opposite sides of the article of footwear 10, each falling on an opposite side of a longitudinal midline LM of the article of footwear 10, partially indicated in FIG. 8. The medial side portion 26 is thus considered opposite to the lateral side portion 24.

The sole structure 14 is rigidly secured to the upper 12 such that the sole structure 14 extends between the upper 12 and a support surface upon which a wearer stands, for example. In effect, the sole structure 14 functions as an intermediate support platform that separates the wearer's foot from the ground. The sole structure 14 may include provisions for attenuating ground reaction forces (i.e., cushioning and stabilizing the foot during vertical and horizontal loading). In addition, sole structure 14 may be configured to provide traction, impart stability, and control or limit various foot motions, such as pronation, supination, or other motions. For example, the disclosed concepts may be applicable to footwear configured for use on any of a variety of surfaces, including indoor surfaces or outdoor surfaces. In some embodiments, the sole structure 14 may be configured to provide traction and stability on hard indoor surfaces (such as hardwood); soft, natural turf surfaces; or on hard, artificial turf surfaces.

In different embodiments, the sole structure 14 may include different components, which may, individually or collectively, provide an article with a number of attributes, such as support, rigidity, flexibility, stability, cushioning, comfort, reduced weight, or other attributes. For example, the sole structure 14 may be fabricated as a single-piece, unitary structure with integrally formed insole, midsole, and outsole sections, defined as a unisole. Alternatively, the sole structure 14 may include discrete components, such as a midsole 19, an outsole 17, and a cushioning layer and/or insole. An insole (not shown) may rest on the sole structure 14 in the foot-receiving cavity 16. The midsole 19 attenuates ground reaction forces (e.g., provides cushioning) when compressed between the foot and the ground during walking, running, or other ambulatory activities. The outsole 17 establishes the ground engaging surface 55 of the article of footwear 10. In one example, the outsole 17 may be one-piece, or may be several outsole components, and may be formed from a wear-resistant material that may be textured to impart traction and/or may include traction elements such as cleats secured to the midsole 19.

The compressible polymer element of the sole structure 14, namely the midsole 19, attenuates ground reaction forces (i.e., provides cushioning) when compressed between the foot and the ground during walking, running, or other ambulatory activities, and may be formed from a compressible polymer element, such as a thermoset or a thermoplastic, for example, a cross-linked thermosetting plastic, a cross-linked thermosetting resin, or a crosslinked thermosetting elastomer (e.g., rubber), a polyurethane foam, ethylvinylacetate (EVA) foam, an ionomeric polymer foam, or the like. In further configurations, the midsole 19 may incorporate fluid-filled chambers, plates, moderators, or other elements that further attenuate forces, enhance stability, or influence the motions of the foot. The midsole 19 may be a single, one-piece midsole, or could be multiple components integrated as a unit.

When the foot is positioned within the foot-receiving interior cavity 16 of the article of footwear 10, the foot is supported on a foot-facing surface of the midsole 19. Optionally, the foot-facing surface of the midsole 19 may be covered by a strobel secured to a lower region of the upper 12. Also, optionally, an insole may rest on the strobel or directly on the sole structure 14 in embodiments without a strobel, in which case the foot is supported by both the sole structure 14 and the insole.

It may be appreciated however that the sole structure 14 is not limited to incorporating traditional sole components and may incorporate various different kinds of elements arranged at the outermost, innermost, and intermediate ‘layers’, or locations, of the sole. Thus, the sole structure 14 can include an outer sole member or element, which may or may not coincide with a conventional ‘outsole’. Likewise, the sole structure 14 may include an inner sole member or element, which may or may not be an ‘insole’. Further, the sole structure 14 can include any number of intermediate and/or middle sole members or elements, which may or may not be a ‘midsole’.

In the present disclosure, the sole structure 14 may define an outer sole surface 13. More particularly, the sole structure 14 may comprise an outsole 17 defining a ground engaging surface 55, and a midsole 19 disposed between the upper 12 and the outsole 17, wherein the midsole 19 defines a midsole outer surface 57. The ground engaging surface 55 and the midsole outer surface 57 cooperate to define the outer sole surface 13.

The sole structure 14, including the midsole 19 and the outsole 17, may include a first plurality of discrete pieces of scrap particulate matter 23. As discussed herein, in a general sense, the article footwear 10 of the present disclosure is designed to be manufactured in an environmentally friendly and sustainable process, which includes techniques to incorporate a first plurality of discrete pieces of scrap particulate matter 23 or “regrind” into the sole structure of a new article of footwear 10. In this way, scrap material may be subsequently divided into the first plurality of discrete pieces of scrap particulate matter 23 or regrind material. As discussed herein, the regrind material, by definition, is material that has undergone at least one processing method and the subsequent sprue, runners, flash, or rejected parts are ground or chopped.

The outsole 17 and the midsole 19 of the sole structure 14 may be fabricated from a mixture of the first plurality of discrete pieces of scrap particulate matter 23 and a virgin polymer material. A virgin material herein may be defined as raw material that has neither been expanded through activation of an intermixed foaming agent nor been formed into an end product. By way of example, the virgin polymer material comprise one of an EVA copolymer having 15-60 mole percent vinyl acetate, a polyurethane (PU) base material, or a synthetic rubber material.

As detailed herein the first plurality of discrete pieces of scrap particulate matter 23 or “regrind” material may be comprised of one of a “grey regrind material” sourced from ground or shredded excess surplus material such as offcuts or scrap material produced during initial shoe formation, “green regrind material” sourced from ground or shredded recycled or discarded post-consumer shoes or other unsellable footwear, or a combination of a grey regrind material and a green regrind material.

In the instance of the sole structure 14, the grey regrind material is a first grey regrind material that includes surplus material from a sole structure of another article of footwear formed of at least one of a thermoplastic elastomer (TPE) plastic and/or ethylene-vinyl acetate (EVA) copolymer plastic, and the green regrind material may be a first green regrind material that includes recycled material from a sole structure of another article of footwear (a used, unsellable, or recycled article of footwear) formed of at least one of a thermoplastic elastomer (TPE) plastic and/or ethylene-vinyl acetate (EVA) copolymer plastic.

The sole structure 14 may comprise a sufficient number of discrete pieces of scrap particulate matter 23 such that more than one of the discrete pieces of scrap particulate matter 23 are at least partially visible on the outer sole surface 13. More particularly, the outsole 17 may include more than fifty (50) discrete pieces of scrap particular matter 23, such that more than one of the discrete pieces of scrap particulate matter 23 are visible on the ground engaging surface 55, and the midsole 19 may include more than fifty (50) discrete pieces of scrap particular matter 23, such that more than one of the discrete pieces of scrap particulate matter 23 are visible on the midsole outer surface 57. In one example, the first plurality of discrete pieces of scrap particulate matter may comprise at least 10% of the sole structure 14 by volume. More particularly, the first plurality of discrete pieces of scrap particulate matter 23 may comprise from about 12% to about 15% of the outsole 17 and from about 10% to about 15% of the midsole 19. Even more particularly, the discrete pieces of scrap particulate matter 23 may comprise more than 10% of the outsole 17 and the midsole 19, such that the discrete pieces of scrap particulate matter 23 comprise about 13.5% of the outsole 17 and about 13.5% of the midsole 19.

It is further envisioned that these discrete pieces of scrap particulate matter 23 may comprise a multitude of colors and irregular shapes. For instance, the sole structure 14 is engineered to generate a randomly interspersed mixture of discrete pieces of scrap particulate matter 23 and virgin polymer material, which is representative sample of which is designated in the inset view of FIG. 9, such that the outer sole surface 13 of the illustrated sole structure 14 is differentiated by a unique color scheme provided by the viewable nature of the first plurality of discrete pieces of scrap particulate matter 23 on the outer sole surface 13.

In another aspect of the disclosure, and as shown in FIGS. 1-6 and 9, the sole structure 14 may further include a plurality of distinctly shaped cavities 35 and a plurality of distinctly shaped protrusions 37 defined by and erratically dispersed on the outer sole surface 13. For instance, the outer surface 13 of the illustrated sole structure 14 is fabricated using a manufacturing process 100 (described below with respect to FIGS. 10-12) that is engineered to generate a randomly interspersed mixture of distinctly shaped and sized cavities 35 and a randomly interspersed mixture of distinctly shaped and sized protrusions 37, which are designated in the inset view of FIG. 9, that project in multiple directions from the midsole outer surface 57 and the ground engaging surface 55 of the sole structure 14. For at least some configurations, the entire outer sole surface 13 of the sole structure 14 is substantially covered with the erratically dispersed cavities 35 and protrusions 37. Optionally, the outsole 17 is provided with fifty (50) or more distinctly shaped cavities 35 and fifty (50) or more distinctly shaped protrusions 37 erratically dispersed on the ground engaging surface 55, and the midsole 19 is provided with fifty (50) or more distinctly shaped cavities 35 and fifty (50) or more distinctly shaped protrusions 37 erratically dispersed on the midsole outer surface 57.

Said another way, the sole structure 14 may be fabricated with an atypical and, in some applications, one of a kind surface topology that may be typified by these distinctly shaped cavities 35 and protrusions 37 (craters and bumps) that comprise irregular shapes, and as such, in combination may take on an indeterminate combination of shapes, including regular and irregular geometric forms, and sizes, as restricted by the total surface area of the outer sole surface 13 to create a unique visual effect wherein the outer sole surface 13 takes on a crater-like appearance. Generally speaking, the surface topology of the sole structure 14 may be characterized by a lack of two structurally identical, equisized sections of surface area as viewed by the naked eye. The cratering and bulging of the sole structure 14 outer sole surface 13 may result from recycled polymers “sweating” entrained oils during the foaming and forming operations described below.

The sole structure 14 may be permanently and/or fixedly attached to one or more portions of the upper 12 (for example, with adhesive, stitching, welding, or other suitable techniques) and may have a configuration that extends between upper 12 and the ground. For purposes of this disclosure, the term “permanently attached” shall refer to two components joined in a manner such that the components may not be readily separated (for example, without destroying one or both of the components). In addition, two components may be “permanently attached” by virtue of being integrally formed, for example, through a molding process.

In general, the upper 12 includes provisions to reduce any tendency of the foot to be pulled away from the sole structure 14 during use. In some embodiments, the upper 12 may be a conventional upper defining and at least partially surrounding an interior volume or cavity 16 for receiving a foot of a wearer. The upper 12 may include a wall 15 that at least partially surrounds the interior volume or cavity 16 and the foot of the wearer. The wall 15 be formed of a variety of materials, such as leather, textiles, polymers, cotton, foam, composites, etc. The wall 15 may include an inner layer 18 of a material that has elasticity, breathability, or both in order to aid with foot insertion and comfort. For example, the inner layer 18 may be a polymeric material or textile material capable of providing elasticity, and may be of a braided construction, a knitted (e.g., warp-knitted) construction, or a woven construction.

The wall 15 at least partially defines the lateral side portion 24 and medial side 26 portion of the upper 12, such that upper 12 may further define a vamp 46 that extends into the forefoot region 34 and the midfoot region 36 on each of the lateral side 24 and the medial side 26 of the upper 12. The wall 15 of the upper 12 may form at least a portion of the vamp 46.

The wall 15 further defines a throat opening 28 disposed between the lateral side portion 24 (FIGS. 1-3) and the medial side portion 26 (FIGS. 4-6). The throat opening 28 may permit a wearer's foot to extend into the interior cavity 16 of the upper 12. The throat opening 28 may be bordered or surrounded by an eyestay reinforcement 48. The throat opening 28 may be further configured to house a closure system 32, such as laces 39 or the like, that may selectively couple the lateral side 24 and the medial side 26 across the throat opening 28, while providing an ability to adjust the girth of the upper 12. The closure system 32 may generally include a unitary closure panel or tongue portion 30 and a plurality of laces 39 each extending between the lateral side portion 24 and the medial side portion 26 of the wall 15. The tongue portion 30 may be integrated with or separately secured to the wall 15. The tongue portion 30 may extend over the instep region of the foot.

In other embodiments, the upper 12 may be configured to provide a ‘tension fit’ about a wearer's foot. As used herein, the term tension fit refers to a fit that ensures the upper is pulled against the foot at all times including on a lower side where the sole of the foot contacts a bottom portion of the upper 12. In some cases, a tension fit upper may be configured so that when no foot is present within the interior cavity 16, the interior cavity 16 has a volume that is smaller than the volume after a foot has been inserted. In other words, the upper 12 may be configured to stretch or expand as a foot is inserted. Such a configuration may provide an upper 12 that ‘stays with’ the foot, and especially the sole of the foot, at all times during any activities (e.g., running, jumping, walking, etc.). A tension fit may or may not require stretching in the upper 12. In some cases, the upper 12 can be configured to stretch significantly when a foot is inserted. In other cases, however, the upper 12 may simply fit the foot very snugly without significant expansion.

In the present disclosure, the upper 12 may comprise a wall 15 that at least partially surrounds the interior volume or cavity 16 and the foot of the wearer. The wall 15 may further comprise an inner layer 18 that defines the interior cavity 16 adapted to receive a foot of a wearer. In some embodiments, the inner layer 18 may include multiple discrete layers. The inner layer 18, thereby has an interior surface 21 that contacts the wearer's foot and an exterior surface 25.

The upper 12 may further include an outer layer 20 formed of a sufficiently transparent or translucent material, such as a transparent or translucent textile, polymer, mesh, or the like. As used herein, a component is “sufficiently transparent” if it has a luminous transmittance (i.e., a percentage of incident light that is transmitted) of at least 80 percent and haze (i.e., percentage of transmitted light that is scattered) of not more than 56 percent. Those skilled in the art will readily understand a variety of methods to determine luminous transmittance and haze of an object, such as the outer layer 20.

The outer layer 20 further defines a surface 31, wherein the surface 31 is an outermost surface of the upper 12. The outer layer 20 may be coupled to the inner layer 18, such that a closed pocket 33 is formed between the inner layer 18 and outer layer 20 of the wall 15. In the present disclosure, the closed pocket 33 is defined as a closed void space between the inner layer 18 and the outer layer 20. The closed pocket 33 is not an open pocket within which inserts may be freely interchanged to change the outward appearance of the article of footwear 10. The closed pocket 33 is sealed, such that after the final forming of the article of footwear 10 is complete, the inner layer 18 and outer layer 20 are permanently attached, i.e., joined in a manner such that the components may not be readily separated (for example, without destroying one or both of the components).

The outer layer 20 may be further coupled to and permanently attached to the inner layer 18 at a plurality of bonded area lines 42. The bonded area lines 42 define a pocket boundary 61 of the closed pocket 33, such that the pocket boundary 61 defines a closed pocket shape. The plurality of bonded area lines 42 may be disposed in a predetermined pattern, such that the closed pocket 33 is divided into a plurality of closed pockets 33 a, 33 b (FIG. 7-8).

The plurality of bonded area lines 42 may be defined in multiple ways. In one example, the plurality of bonded area lines 42 may be defined as a plurality of pocket boundary stitch lines. In this way, the inner layer 18 and the outer layer 20 may be permanently attached via stitching at the bonded area lines 42, such that each of the plurality of pockets 33 a, 33 b is bordered along an entirety of a respective outer boundary 61 by a stitch line. In another example, the plurality of bonded area lines 42 may be defined as a plurality of pocket boundary weld junctions. In this way, the inner layer 18 and the outer layer 20 may be permanently attached via welding, i.e., the inner layer 18 is welded to the outer layer 20 at the plurality of bonded area lines 42, such that each of the plurality of pockets 33 a, 33 b is bordered along an entirety of a respective outer boundary 61 by a weld junction. In yet another example, the plurality of bonded area lines 42 may be defined as a plurality of pocket boundary baffle walls. In this way, the inner layer 18 and the outer layer 20 may be permanently attached via a baffle wall at the plurality of bonded area lines 42, such that each of the plurality of pockets 33 a, 33 b is bordered along an entirety of a respective outer boundary 61 by a baffle wall that extends between the inner layer 18 and the outer layer 20. In such an example, the pocket boundary baffle walls may be comprised of the same material as the outer layer 20.

The upper 12 may further include a plurality of auxiliary stitch lines 44 that couple or permanently attach the inner layer 18 to the outer layer 20. In this way, each of the auxiliary stitch lines 44 extend between the inner layer 18 and the outer layer 20. The auxiliary stitch 44 lines are often aesthetic features of the article of footwear 10, and as such are disposed in a predetermined pattern on the upper 12. In each predetermined pattern, at least one of the auxiliary stitch lines 44 traverses at least one of the closed pockets 33 a, 33 b.

The upper 12 may further include a layer of scrap particulate matter 54 (FIG. 7) disposed between the inner layer 18 and the outer layer 20 and dispersed throughout the closed pocket 33. The layer of scrap particulate matter 54 is disposed between the inner layer 18 and the outer layer 20 and dispersed throughout the closed pocket 33. In this way, the layer of scrap particulate matter 54 is positioned on the upper 12 in the location of the respective closed pocket 33.

As shown in FIGS. 1-6, the closed pocket 33 may be disposed in any one of or each of the forefoot region 34, the midfoot region 36, the heel region 38, and the tongue portion 30 of the upper 12. In one example, the closed pocket 33 may be disposed in the forefoot region 34 (FIGS. 1, 4, 7, and 8). In another example, the closed pocket 33 may be disposed in the midfoot region 36 (FIGS. 2 and 5). In another example, the closed pocket 33 may be disposed in the heel region 38 (FIGS. 3 and 6). In another example, the closed pocket 33 may be disposed in the tongue portion 30 (FIG. 8). In one particular example embodiment (FIGS. 1, 4, 7, and 8), the wall 15 of the upper 12 at least partially defines a vamp 46 that extends into the forefoot region 34 and the midfoot region 36 on each of the lateral side 24 and the medial side 26 of the upper 12. In such an example, the closed pocket 33 may be positioned or disposed in the vamp 46.

In one example, the layer of scrap particulate matter 54 comprises a second plurality of discrete pieces of scrap particulate matter or regrind 22, which may be comprised of a “grey regrind material” sourced from ground or shredded excess surplus material such as offcuts or scrap material produced during initial shoe formation, a “green regrind material” sourced from ground or shredded recycled or discarded post-consumer shoes or other unsellable footwear, or a combination of a grey regrind material and a green regrind material.

In a first instance, the second plurality of discrete pieces of scrap particulate matter 22 may comprise a grey regrind material, defined as a first grey regrind material that comprises surplus material from a sole structure of another article of footwear formed of at least one of a thermoplastic elastomer (TPE) plastic and/or ethylene-vinyl acetate (EVA) copolymer plastic. In a second instance, the second plurality of discrete pieces of scrap particulate matter 22 may comprise a grey regrind material, defined as a second grey regrind material that comprises surplus material from an upper of another article of footwear comprising at least one of a leather material, a textile material, a polymer material, or a foam material, e.g., in one example instance the second grey regrind material may be ground or shredded recycled yarn salvaged from a production loom. In a third instance, the second plurality of discrete pieces of scrap particulate matter 22 may comprise a green regrind material, defined as a first green regrind material comprises recycled material from a sole structure of another article of footwear formed of at least one of a thermoplastic elastomer (TPE) plastic and/or ethylene-vinyl acetate (EVA) copolymer plastic. In a fourth instance, the second plurality of discrete pieces of scrap particulate matter 22 may comprise a green regrind material, defined as a second green regrind material that comprising recycled material from an upper of another article of footwear formed of at least one of a leather material, a textile material, a polymer material, or a foam material.

In one example, the layer of scrap particulate matter 54 is defined as a second plurality of discrete pieces of scrap particulate matter or regrind 22, which may be sprayed or blown into the pocket 33 via a filling machine, such that each of the discrete pieces of scrap particulate matter 22 or regrind granules are free floating within the pocket 33.

In another example, wherein the second plurality of discrete pieces of scrap particulate matter 22 is one of the second grey regrind material and the second green regrind material, wherein the discrete pieces of scrap particulate 22 are woven together in a mesh-like configuration to comprise the layer of scrap particulate matter 54.

In still another example, as shown in FIG. 7, the layer of scrap particulate matter 54 includes a second plurality of discrete pieces of scrap particulate matter or regrind 22 and a resin binder, that may include a virgin polymer. In this way, the second plurality of discrete pieces of scrap particulate matter or regrind 22 may be adhered together with a resin binder and then inserted into the closed pocket 33 in a layer formation as shown in FIG. 7. More particularly, the second plurality of discrete pieces of scrap particulate matter 22 may be mixed with a resin binder to form a mixture. The second plurality of discrete pieces of scrap particulate matter 22 may make up from about 3% to about 15% of the mixture so that the same may be readily visible within the mixture. The mixture of resin binder and second plurality of discrete pieces of scrap particulate matter 22 may be placed in a mixing container which is then placed inside of a mixing machine and mixed sufficiently to coat all outer surfaces of the discrete pieces of scrap particulate matter 22 with the resin binder. The mixture may then be removed from the mixing machine and formed into a sheet-like formation having a thickness 52. In some embodiments, the thickness 52 may be from about 0.07 millimeters to about 1.3 millimeters, and more particularly about 1.0 millimeters. In this way, the layer of scrap particulate matter 54 may be a die cut layer defining a layer boundary 59, wherein the layer boundary 59 defines a layer shape such that the layer shape is substantially identical to the closed pocket shape. In this way, the layer of scrap particulate matter 54 fits seamlessly into the closed pocket 33 defined between the inner layer 18 and the outer layer 20, as shown by example in FIG. 7.

Irrespective of where the closed pocket 33 is positioned on the upper 12, and the make-up of the layer of scrap particulate matter 54, due to the transparent and/or translucent nature of the outer layer 20, the layer of scrap particulate matter 54, once positioned between the inner layer 18 and outer layer 20 is at least partially visible through the outer layer 20. Said another way, the outer layer 20 is formed of a sufficiently transparent material, such that the layer of scrap particulate matter 54 is at least partially visible through the outer layer 20.

In this way, the scrap particulate matter 22, 23, e.g., the grey regrind material, the green regrind material, or the combination thereof, may be readily seen by viewers or wearers of the article of footwear 10 to showcase not only the desirable and unique aesthetic design, but also the sustainable and environmentally conscience method of manufacture 100, wherein scrap material, manufacturing surplus material, or recycled or reclaimed material from a discarded or unsellable footwear application, is utilized in the formation of a newly-formed shoe, to reduce material waste.

Such a method of manufacturing 100 includes techniques to incorporate a first plurality of discrete pieces of scrap particulate matter 23 or “regrind” into a sole structure 14 of a new article of footwear 10 and a second plurality of discrete pieces of scrap particulate matter 22 or “regrind” into the upper 12 of a new article of footwear 10. Accordingly, as detailed by the method of manufacture 100 disclosed herein and shown by example in FIGS. 1-12, scrap or surplus material from footwear manufacturing and/or recycled waste material from recycled or discarded post-consumer shoes or unsellable footwear may be utilized in the formation a newly formed article of footwear 10.

Method 100 of FIG. 10 may be initiated, e.g., responsive to receipt of an activation command signal received from a human machine interface (HMI) of a central control terminal. Initial stages of the manufacturing process may comprise receiving, supplying, accessing, and/or utilizing (collectively “providing”) the various materials, tools and machines needed to manufacture the article of footwear 10. At step 101, for example, a batch of scrap material is accessed from an available store of scrap material. More particularly, at step 101 scrap material is obtained or harvested from a surplus material such as offcuts or scrap material produced initial shoe formation and/or from recycled or discarded waste material from post-consumer shoes or unsellable footwear.

Once the scrap material is received and any attendant sorting, cleaning, or other pre-processing is completed thereon, at step 102 the scrap material may be subsequently divided into a plurality of discrete pieces of scrap particulate matter 22, 23 or regrind material. More particularly, the scrap material may be divided into a first plurality of discrete pieces of scrap particulate matter 23 and a second plurality of discrete pieces of scrap particulate matter 22.

As discussed herein, the regrind material, by definition, is material that has undergone at least one processing method and the subsequent sprue, runners, flash, or rejected parts are ground or chopped. As such, in one example, dividing the scrap material into the discrete pieces of scrap particulate matter 22, 23 may be completed via a grinding process, i.e., inserting the scrap material into a grinding machine to produce the first plurality of discrete pieces of scrap particulate matter 23 and the second plurality of discrete pieces of scrap particulate matter 22. In another example, dividing the scrap material into the plurality of discrete pieces of scrap particulate matter 22, 23 may be completed via a shredding process, i.e., inserting the scrap material into a shredding machine to produce the first plurality of discrete pieces of scrap particulate matter 23 and the second plurality of discrete pieces of scrap particulate matter 22.

Given that the discrete pieces of scrap particulate matter 22, 23 or regrind is formed via a grinding process or a shredding process in step 102, the shredded or ground nature of the regrind may result in each discrete piece of scrap particulate matter 22 or regrind granule having a different shape. Said another way, the discrete pieces of scrap particulate matter 22, 23 or regrind granules do not have a regular or normalized shape, as when the scrap material goes through a grinding machine or shredding machine there is the potential to get a wide range of granule sizes, including but not limited to fine, small dust like particles to up to 0.25 inch or larger pieces of material. Said another way, discrete pieces of scrap particulate matter 22, 23 or regrind granules do not have a regular or normalized shape and each discrete piece of scrap particulate matter 22, 23 or regrind granule may have a unique and different shape. Alternate manners of creating the discrete pieces of scrap particulate matter 22, 23 or regrind material include the techniques described in U.S. Pat. No. 9,132,430, which is incorporated by reference in its entirety.

As indicated herein, the scrap material is obtained or harvested from a surplus material such as offcuts or scrap material produced initial shoe formation and/or recycled or discarded post-consumer shoes or other unsellable footwear. In one example, the scrap material is obtained or harvested from surplus material, such as offcuts or scrap material produced during initial shoe formation of another article of footwear, such that the regrind material 22, 23 produced at step 102 is defined a “grey regrind material”. Grey regrind material may include at least one of a leather material, a textile material, a polymer material, a foam material, or elastomeric material, in the form of ground or shredded pieces of surplus material, such as offcuts or other scrap from at least one of an upper and a sole structure of another article of footwear. In one example the grey regrind material is a first grey regrind material that comprises pieces of surplus material from the sole structure of another article of footwear, the grey regrind material may comprise at least one of a foamed-thermoplastic material or a thermoset material. In another example, the grey regrind material is a second grey regrind material that comprises pieces of surplus material from the upper of another article of footwear such as yarn, thread, tags, textiles, upper foam, leather or polymer offcuts, and the like, the grey regrind material may comprise at least one of a leather material, a textile material, and a foam material. In still another example, the grey regrind material may comprise a mixture of the first grey regrind material and the second grey regrind material, such that the grey regrind material comprises surplus material from each of the upper and sole structure of another article of footwear.

In another example, the scrap material is obtained or harvested from recycled or discarded post-consumer shoes or unsellable footwear, such that the regrind material 22, 23 produced at step 102 is defined a “green regrind material”. Green regrind material may include at least one of a leather material, a textile material, a polymer material, a foam material, or elastomeric material, in the form of ground or shredded pieces of recycled or discarded post-consumer shoes or unsellable footwear. In one example the green regrind material is a first green regrind material that comprises pieces of the sole structure of recycled or discarded post-consumer shoes or unsellable footwear, the green regrind material may comprise at least one of a foamed-thermoplastic material or a thermoset material. Suitable examples of foamed-thermoplastic materials may include a polyurethane foam material, an Ethylene-Vinyl Acetate (EVA) foam material, an ionomeric foam material, or the like. Examples of a thermoset polymer material may include a cross-linked thermosetting plastic, a cross-linked thermosetting resin, or a cross-linked thermosetting elastomer, e.g., rubber. In another example, the green regrind material is a second green regrind material that comprises pieces from the upper of recycled or discarded post-consumer shoes or unsellable footwear such as yarn, thread, tags, textiles, upper foam, leather, or polymer pieces, and the like, the green regrind material may comprise at least one of a leather material, a textile material, and a foam material. In still another example, the green regrind material may comprise a mixture of the first green regrind material and the second green regrind material, such that the green regrind material comprises pieces from each of the upper and sole structure of recycled or discarded post-consumer shoes or unsellable footwear. The scrap particulate matter 22, 23 or regrind material may also be formed of a combination of green regrind material and grey regrind material.

At step 103, the sole structure 14 of the article of footwear is formed, wherein the first plurality of discrete pieces of scrap particulate matter 23 are incorporated into the sole structure 14, such that the first plurality of discrete pieces of scrap particulate matter 23 comprise a sufficient amount of the sole structure 14, such that more than one of the first plurality of discrete pieces of scrap particulate matter 23 is visible on an a formed outer sole surface 13 of the sole structure 14. Step 103 is further detailed in FIG. 11 via sub-steps 201-204.

In FIG. 11, at step 201 the first plurality of discrete pieces of scrap particulate matter 23 is mixed with a resin binder and a foaming agent to collectively form a sole structure mixture. The discrete pieces of scrap particulate matter 23 may comprise from about 10% to about 15% of the mixture so that the same may be readily visible within the mixture. The resin binder may a composition of virgin polymer material, wherein a virgin material is a raw material has neither been expanded through activation of an intermixed foaming agent nor been formed into an end product. By way of example, the virgin polymer material comprise one of an EVA copolymer having 15-60 mole percent vinyl acetate, a polyurethane (PU) base material, or a synthetic rubber material. The sole structure mixture of resin binder and discrete pieces of scrap particulate matter 23 may be placed in a mixing container which is then placed inside of a mixing machine and mixed sufficiently to coat all outer surfaces of the discrete pieces of scrap particulate matter 23 with the resin binder.

In at least some implementations, a foaming agent is incorporated as a separate ingredient into the mixture of recycled and virgin polymer material for invoking the expansion of the mixture during molding. This foaming agent may be thermally decomposable, and may be selected from organic and inorganic chemical foaming agents. The foaming agent may comprise any substance which, alone or in combination with other substances, is capable of producing a cellular structure in a plastic. Foaming agents may include compressed gases that expand when pressure is released, soluble solids that leave pores when leached out, liquids that develop cells when they change to gases, and chemical agents that decompose or react under the influence of heat to form a gas. By way of example, the chemical foaming agent may range from a simple salt, such as ammonium or sodium bicarbonate, to a complex nitrogen releasing agent. For at least some applications, the foaming agent includes azohexahydrobenzonitrile, diazocarbamide, azodicarbonamide, diazodiaminobenzene, benzenesulfonylhydrazide, terephthalazide, sulfonylhydrazide compounds, sodium bicarbonate, ammonium bicarbonate, or any combination thereof. The decomposition temperature of the foaming agent may be from about 120° C. to about 200° C.

Numerous other additives may be incorporated into the sole structure mixture prior to introduction into the final mold for forming the sole structure 14. As an example, a chemical foaming auxiliary agent may be added to lower the decomposition temperature of the foaming agent. Conversely, a chemical foaming inhibitor may be added in measure to raise the decomposition temperature of the thermally decomposable foaming agent. Another option may include adding a metered amount of a chemical crosslinking agent to link the polymer chain of the scrap particulate matter to the polymer chain of the virgin material. Under the temperature conditions of the reaction, a peroxide-based agent may be activated to initiate the process of crosslinking by removing a hydrogen atom from a polymer backbone to thereby provide sites for crosslinking. The nature and level of the crosslinking agent may be selected to provide suitable foaming and crosslinking in conjunction with the foaming agent.

Other components can be added to the polymer compositions, including fillers, activators, homogenizing agents, pigments, fire retardants, lubricants, and other suitable additives. Non-limiting examples of filler materials include talcum powder, mica silicate, bearing sulfate, magnesium hydroxide, magnesium carbonate, magnesium silicate, calcium carbonate, and other commercially available fillers. The polymer compositions can also contain rubber fillers, such as ethylene propylene rubber (EPR), styrene isoprene styrene (SIS) copolymer rubber, styrene butadiene rubber, as well as other polyolefin resins, in addition to EVA or TPE base materials. In other examples, polyethylene wax may be used as a processing agent, stearic acid may be used as a lubricant, dicumyl peroxide may be used as a polymerization initiator, zinc oxide may be used as an activator for the foaming agent, while titanium dioxide may be used as a white pigment.

Once the sole structure mixture is complete and ready for molding the sole structure mixture is placed into an internal cavity of the final mold that is shaped like the desired sole structure 14, as indicated at process block 202. Optionally, prior to placing the sole structure mixture into an internal cavity of a final mold, a release agent may be applied to an exposed surface of an exposed surface of each complementary recess of the final mold to facilitate separation of the sole structure 14 from the final mold assembly after its formation.

At step 203, the sole structure 14 may be formed via compression molding, injection molding, two-shot molding, insert molding, co-injection molding or any other technique for forming the desired soles structure 14, that includes heating the sole structure mixture past a threshold activation temperature of the foaming agent such that the foaming agent causes the sole structure mixture to expand and fill the internal cavity of the final mold.

At step 204, the formed sole structure 14 may then be extracted from the final mold.

Referring back to FIG. 10, at step 104, the upper 12 of the article of footwear 10 is formed including inserting the second plurality of discrete pieces of scrap particulate matter 22, e.g., the grey regrind material, the green regrind material, or the combination thereof, between the inner layer 18 of the wall 15 of the upper 12 and the outer layer 20 of the wall 15 of the upper 12 and further dispersed throughout a closed pocket 33 formed between in the inner layer 18 and the outer layer 20. Step 104 is further detailed in FIG. 12 via sub-steps 301-306.

In examples wherein, the closed pocket 33 is a plurality of closed pockets 33 a, 33 b, the discrete pieces of scrap particulate matter 22 are dispersed throughout each of the closed pockets 33 a, 33 b. The discrete pieces of scrap particulate matter 22 may be inserted between the inner layer 18 of and the outer layer 20 and further dispersed throughout the closed pocket 33 via a variety of processes.

In one example, the regrind 22 may be sprayed or blown or otherwise positioned within the pocket 33 via a filling machine, such that each of the discrete pieces of scrap particulate matter 22 or regrind granules are free floating within the pocket 33.

In another example, the scrap particulate matter 22 may be adhered together and then inserted into the closed pocket 33 in a layer formation. More particularly, at step 301, the discrete pieces of scrap particulate matter 22 may be mixed with a resin binder to form an upper mixture. The discrete pieces of scrap particulate matter 22 may make up from about 3% to about 15% of the upper mixture so that the same may be readily visible within the mixture. The mixture of resin binder and discrete pieces of scrap particulate matter 22 may be placed in a mixing container which is then placed inside of a mixing machine and mixed sufficiently to coat all outer surfaces of the discrete pieces of scrap particulate matter 22 with the resin binder. The upper mixture may then be removed from the mixing machine and formed into a sheet-like formation having a thickness 52.

At step 302, the sheet-like formation or layer of upper mixture may be placed in a dryer for 30 minutes at 80 degrees Celsius, for example. Once dried, the sheet-like formation may be compression molded or thermoformed to produce a layer of scrap particulate matter 54 having the thickness 52, as shown in FIG. 7. The thickness 52 may be from about 0.7 millimeters to about 1.3 millimeters, and more particularly about 1.0 millimeters.

At step 303, the layer of scrap particulate matter 54 may be die cut into a predetermined layer shape, wherein the layer shape is defined by a layer boundary 59 and is substantially identical to the closed pocket shape defined by the pocket boundary 61. In this way, the layer of scrap particulate matter 54 fits seamlessly into the closed pocket 33 defined between the inner layer 18 and the outer layer 20.

At step 304, the layer shape may be placed upon and in contact with the outer layer 20. At step 305, the inner layer 18 may be positioned over the layer shape and the outer layer 20, such that the inner layer 18 and the outer layer 20 form the closed pocket 33 about a perimeter or outer layer boundary 59 of the layer of scrap particulate matter 54, such that the layer of scrap particulate matter 54 is disposed within the closed pocket 33.

At step 306, the outer layer 20 may be further coupled to and permanently attached to the inner layer 18 at a plurality of bonded area lines 42. The plurality of bonded area lines 42 may be disposed in a predetermined pattern, such that the closed pocket 33 and the layer shape are enclosed by the bonded area lines 42.

The plurality of bonded area lines 42 may be defined in multiple ways. In one example, the plurality of bonded area lines 42 may be defined as a plurality of pocket boundary stitch lines, such that coupling the inner layer 18 of the wall 15 of the upper 12 to the outer layer 20 of the wall 15 of the upper includes stitching the inner layer 18 to the outer layer 20 at each of the plurality of bonded area lines 42, such that each of the bonded area lines is defined as a stitch line and each of the plurality of pockets 33 a, 33 b is bordered along an entirety of a respective outer boundary by a stitch line.

In another example, the plurality of bonded area lines 42 may be defined as a plurality of pocket boundary adhesive junctions, such that coupling the inner layer 18 of the wall 15 of the upper 12 to the outer layer 20 of the wall 15 of the upper 12 includes applying an adhesive to one of the inner layer 18 and the outer layer 20 at the bonded area lines 42, and joining the inner layer 18 and the outer layer 20 at the bonded area lines 42.

In another example, the plurality of bonded area lines 42 may be defined as a plurality of pocket boundary weld junctions. In this way, the inner layer 18 and the outer layer 20 may be permanently attached via welding, i.e., the inner layer 18 is welded to the outer layer 20 at the plurality of bonded area lines 42, such that each of the plurality of pockets 33 is bordered along an entirety of a respective outer boundary by a weld junction. As utilized herein, the term “welding” or variants thereof (such as “thermal bonding”) is defined as a technique for securing two elements to one another that involves a softening or melting of a polymer material within at least one of the elements such that the materials of the elements are secured to each other when cooled. Similarly, the term “weld” or variants thereof (e.g., “thermal bond”) is defined as the bond, link, or structure that joins two elements through a process that involves a softening or melting of a polymer material within at least one of the elements such that the materials of the elements are secured to each other when cooled.

Welding generally produces a heat-affected zone in which the materials of the two joined components are intermingled. This heat-affected zone may be considered a “weld” or “thermal bond.” Further, welding may involve (a) the melting or softening of two layers that include polymer materials, such that the polymer materials from each layer intermingle with each other (e.g., diffuse across a boundary layer between the polymer materials) and are secured together when cooled, as well as (b) the melting or softening a polymer material in a first layer such that the polymer material extends into or infiltrates the structure of a second layer (e.g., infiltrates crevices or cavities formed in the second layer or extends around or bonds with filaments or fibers in the second layer) to secure the layers together when cooled. Further, welding may occur when only one layer includes a polymer material, when both layers include polymer materials, or when a polymer material or resin is disposed between the respective layers.

In one embodiment, to effectuate the weld, a resin binder is applied to the inner layer 18 at each of the bonded area lines 42, the resin binder is heated to a viscous state, such that the resin binder infiltrates the inner layer 18 and the outer layer 20 at each of the plurality of bonded area lines 42, and the resin binder is cooled to a solid state.

In another embodiment, wherein the one of the inner layer 18 and the outer layer 20 is formed of a thermoplastic material, to effectuate the weld, the respective layer 18, 20 formed of the thermoplastic material is heated to a viscous state, such that the thermoplastic layer infiltrates the other of the inner layer 18 and the outer layer 20 at the plurality of bonded area lines 42, and the thermoplastic layer is cooled to a solid state.

Referring back to FIG. 10, at step 105 the formed upper 12 and the formed sole structure 14 may be fixedly attached to one another, via an adhesive, stitching, welding, or other suitable techniques to form a finished article of footwear 10.

The detailed description and the drawings or figures are supportive and descriptive of the present teachings, but the scope of the present teachings is defined solely by the claims. While some of the best modes and other embodiments for carrying out the present teachings have been described in detail, various alternative designs and embodiments exist for practicing the present teachings defined in the appended claims.

While various embodiments have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the embodiments. Any feature of any embodiment may be used in combination with or substituted for any other feature or element in any other embodiment unless specifically restricted. Accordingly, the embodiments are not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims.

Benefits, other advantages, and solutions to problems, and any element or elements that may cause any benefit, advantage, or solution to occur or become more pronounced, however, are not to be construed as critical, required, or essential features or elements of any or all of the claims, unless such benefits, advantages, solutions, or elements are expressly stated in such claims. 

What is claimed is:
 1. An article of footwear comprising: an upper including a wall that at least partially surrounds an interior volume operative to receive a foot of a wearer, wherein the wall comprises: an inner layer; an outer layer coupled to the inner layer, such that the inner layer and the outer layer define a closed pocket therebetween; a layer of scrap particulate matter disposed between the inner layer and the outer layer and dispersed throughout the closed pocket, and wherein the outer layer is formed of an at least partially transparent material, such that the layer of scrap particulate matter is at least partially visible through the outer layer; a sole structure configured to support thereon the foot of the wearer and fixedly attached to the upper, the sole structure comprising a first plurality of discrete pieces of scrap particulate matter and defining an outer sole surface, such that more than one of the discrete pieces of scrap particulate matter of the first plurality of discrete pieces of scrap particulate matter are at least partially visible on the outer sole surface; and wherein the sole structure includes a plurality of distinctly shaped cavities and a plurality of distinctly shaped protrusions defined by and erratically dispersed on the outer sole surface; and wherein the layer of scrap particulate matter in the upper comprises a leather material, a textile material, a polymer material, or a foam material and the plurality of discrete pieces of scrap particulate matter in the sole structure comprises a rubber, a thermoplastic elastomer (TPE), and/or ethylene-vinyl acetate (EVA) copolymer.
 2. The article of footwear of claim 1 wherein the layer of scrap particulate matter comprises at least one of a green regrind material or a grey regrind material.
 3. The article of footwear of claim 2 wherein the first plurality of discrete pieces of scrap particulate matter comprises at least 10% of the sole structure.
 4. The article of footwear of claim 2 wherein the sole structure further comprises an outsole defining a ground engaging surface, wherein the outsole is fabricated from a mixture of the first plurality of discrete pieces of scrap particulate matter and virgin polymer material.
 5. The article of footwear of claim 4 wherein and the first plurality of discrete pieces of scrap particulate matter comprises at least one of a green regrind material or a grey regrind material.
 6. The article of footwear of claim 5 wherein the outsole includes more than 50 of the discrete pieces of scrap particulate matter of the first plurality of discrete pieces of scrap particulate matter, such that more than one of the discrete pieces of scrap particulate matter are visible on the ground engaging surface.
 7. The article of footwear of claim 6 wherein the first plurality of discrete pieces of scrap particulate matter comprise from about 12% to about 15% of the outsole.
 8. The article of footwear of claim 6 wherein the sole structure further comprises a midsole disposed between the upper and the outsole, the midsole defining a midsole outer surface, wherein the ground engaging surface and the midsole outer surface cooperate to collectively define the outer sole surface; and wherein the midsole is fabricated from a mixture of the first plurality of discrete pieces of scrap particulate matter and virgin polymer material.
 9. The article of footwear of claim 8 wherein the midsole includes more than 50 of the discrete pieces of scrap particulate matter of the first plurality of discrete pieces of scrap particulate matter, such that more than one of the discrete pieces of scrap particulate matter are visible on the midsole outer surface.
 10. The article of footwear of claim 9 wherein the first plurality of discrete pieces of scrap particulate matter comprise form about 12% to about 15% of the midsole.
 11. The article of footwear of claim 9 wherein: the ground engaging surface defines at least 50 of the distinctly shaped cavities and at least 50 of the distinctly shaped protrusions erratically dispersed thereon; and the midsole outer surface defines at least 50 of the distinctly shaped cavities and at least 50 of the distinctly shaped protrusions erratically dispersed thereon.
 12. The article of footwear of claim 11 wherein the ground engaging surface and the midsole outer surface cooperate to collectively define the outer sole surface, such that the outer sole surface is substantially covered with the erratically dispersed distinctly shaped cavities and distinctly shaped protrusions.
 13. The article of footwear of claim 12 wherein: the outer layer is coupled to the inner layer at a plurality of bonded area lines, and wherein the plurality of bonded area lines is defined as at least one of a plurality of pocket boundary stitch lines, a plurality of pocket boundary weld junctions, or a plurality of pocket boundary baffle walls extending between the inner layer and the outer layer; the plurality of bonded area lines define a pocket boundary of the closed pocket; and the pocket boundary of the closed pocket defines a closed pocket shape.
 14. The article of footwear of claim 13 wherein: the upper has a lateral side and a medial side and further defines a forefoot region, a midfoot region, and a heel region; each of the lateral side and the medial side extend into the forefoot region, the midfoot region, and the heel region; the upper further defines a vamp that extends into the forefoot region and the midfoot region on each of the lateral side and the medial side; the wall forms at least a portion of the vamp; and wherein the closed pocket is disposed in one of the vamp, the midfoot region, or the heel region.
 15. The article of footwear of claim 14 wherein the layer of scrap particulate matter is defined as a second plurality of discrete pieces of scrap particulate matter, such that each of the second plurality of discrete pieces of scrap particulate matter are free floating within the pocket.
 16. The article of footwear of claim 14 wherein the layer of scrap particulate matter further comprises a second plurality of discrete pieces of scrap particulate matter secured to one another via a resin binder, such that the layer of scrap particulate matter is a die cut layer of scrap particulate matter defining a layer boundary and a thickness of from about 0.07 millimeters to about 1.3 millimeters; and wherein the layer boundary defines a layer shape, wherein the layer shape is substantially identical to the closed pocket shape.
 17. The article of footwear of claim 12 wherein: the first plurality of discrete pieces of scrap particulate matter is further defined as at least one of ground pieces of at least one of the grey regrind material or the green regrind material or shredded pieces of the grey regrind material or the green regrind material; and the layer of scrap particulate matter comprises a second plurality of discrete pieces of scrap particulate matter, wherein the second plurality of discrete pieces of scrap particulate matter are defined as at least one of ground pieces at least one of the grey regrind material or the green regrind material or shredded pieces of the grey regrind material or the green regrind material.
 18. The article of footwear of claim 17 wherein: the first plurality of discrete pieces of scrap particulate matter is a plurality of discrete pieces of a first grey regrind material, wherein the first grey regrind material comprises surplus material from a sole structure of another article of footwear; and the second plurality of discrete pieces of scrap particulate matter is a plurality of discrete pieces of a second grey regrind material, wherein the second grey regrind material comprises surplus material from an upper of another article of footwear.
 19. The article of footwear of claim 17 wherein: the first plurality of discrete pieces of scrap particulate matter is a plurality of discrete pieces of a first green regrind material comprising recycled material from a sole structure of another article of footwear; and the second plurality of discrete pieces of scrap particulate matter is a plurality of discrete pieces of a second green regrind material comprising recycled material from an upper of another article of footwear.
 20. The article of footwear of claim 17 wherein: the first plurality of discrete pieces of scrap particulate matter is a plurality of discrete pieces of a first grey regrind material, wherein the first grey regrind material comprises surplus material from a sole structure of another article of footwear; and the second plurality of discrete pieces of scrap particulate matter is a plurality of discrete pieces of a second green regrind material, wherein the second green regrind material comprising recycled material from an upper of another article of footwear.
 21. The article of footwear of claim 17 wherein: the first plurality of discrete pieces of scrap particulate matter is a plurality of discrete pieces of a first green regrind material, wherein the first green regrind material comprises comprising recycled material from a sole structure of another article of footwear; and the second plurality of discrete pieces of scrap particulate matter is a plurality of discrete pieces of a second grey regrind material, wherein the second grey regrind material comprises surplus material from an upper of another article of footwear. 